Robot assisted direct-to-pack sortation systems

Abstract

Systems, methods, and computer-readable media are disclosed for robot assisted direct-to-pack sortation. In one embodiment, an example autonomous robot may include one or more forks, and a controller configured to determine that a first container is empty, transport the first container to a pick docking station, retrieve a second container from an induct station, wherein the second container is full, transport the second container to a buffer area, determine that the first container is full, and transport the first container to the buffer area.

That which is claimed is: 
     
         1 . A system to sort bulky items, the system comprising:
 a first container comprising fencing along three walls, an open fourth wall, and a platform having slots;   an autonomous robot comprising forks configured to engage the slots on the platform of the first container, wherein the autonomous robot is configured to raise and transport the first container; and   a controller configured to:
 determine that the first container is empty; 
 cause the autonomous robot to transport the first container to a pick docking station; 
 cause the autonomous robot to retrieve a second container from an induct station, wherein the second container is full; 
 cause the autonomous robot to transport the second container to a buffer area; 
 cause the autonomous robot to transport the second container to a packing station; 
 determine that the first container is full; 
 cause the autonomous robot to retrieve a third container from the buffer area, wherein the third container is empty; 
 cause the autonomous robot to transport the third container to the pick docking station; and 
 cause the autonomous robot to transport the first container to the buffer area. 
   
     
     
         2 . The system of  claim 1 , wherein the second container is transported while the first container is being filled. 
     
     
         3 . The system of  claim 1 , wherein the controller is further configured to:
 determine a time sensitivity metric associated with a fourth container; and   transport the fourth container directly to the packing station while bypassing the buffer area based at least in part on the time sensitivity metric.   
     
     
         4 . The system of  claim 1 , wherein the system comprises the pick docking station, the induct station, the buffer area, and the packing station. 
     
     
         5 . An autonomous robot comprising:
 memory comprising computer-executable instructions; and   one or more computer processors configured to access the memory and execute the computer-executable instructions to:
 determine that a first container is empty; 
 transport the first container to a pick docking station; 
 retrieve a second container from an induct station, wherein the second container is full; 
 transport the second container to a buffer area; 
 determine that the first container is full; and 
 transport the first container to the buffer area. 
   
     
     
         6 . The autonomous robot of  claim 5 , wherein the second container is transported while the first container is being filled. 
     
     
         7 . The autonomous robot of  claim 5 , wherein the one or more computer processors are further configured to execute the computer-executable instructions to:
 determine a time sensitivity metric associated with a third container; and   transport the third container directly to the packing station while bypassing the buffer area based at least in part on the time sensitivity metric.   
     
     
         8 . The autonomous robot of  claim 5 , wherein the one or more computer processors are further configured to execute the computer-executable instructions to:
 determine that a packing station has an opening; and   transport the second container from the buffer area to the packing station.   
     
     
         9 . The autonomous robot of  claim 5 , wherein the one or more computer processors are further configured to execute the computer-executable instructions to:
 retrieve a third container from the buffer area, wherein the third container is empty; and   transport the third container to the pick docking station.   
     
     
         10 . The autonomous robot of  claim 5 , wherein the autonomous robot comprises one or more forks. 
     
     
         11 . The autonomous robot of  claim 10 , wherein the first container is a cage comprising fencing along three walls, an open fourth wall, and a platform having slots configured to receive the one or more forks. 
     
     
         12 . The autonomous robot of  claim 5 , wherein the second container is full of items individually weighing at least 20 pounds. 
     
     
         13 . The autonomous robot of  claim 5 , wherein the one or more computer processors are further configured to execute the computer-executable instructions to:
 coordinate transport of the first container with a fleet of autonomous robots.   
     
     
         14 . A method for transporting bulky items by an autonomous robot, the method comprising:
 determining, by a controller, that a first container is empty;   transporting the first container to a pick docking station;   retrieving a second container from an induct station, wherein the second container is full;   transporting the second container to a buffer area;   determining, by the controller, that the first container is full; and   transporting the first container to the buffer area.   
     
     
         15 . The method of  claim 14 , wherein the second container is transported while the first container is being filled. 
     
     
         16 . The method of  claim 14 , further comprising:
 determining, by the controller, a time sensitivity metric associated with a fourth container; and   transporting the fourth container directly to the packing station while bypassing the buffer area based at least in part on the time sensitivity metric.   
     
     
         17 . The method of  claim 14 , further comprising:
 determining, by the controller, that a packing station has an opening; and   transporting the second container from the buffer area to the packing station.   
     
     
         18 . The method of  claim 14 , further comprising:
 retrieving a third container from the buffer area, wherein the third container is empty; and   transport the third container to the pick docking station.   
     
     
         19 . The method of  claim 14 , further comprising:
 coordinating, by the controller, transport of the first container with a fleet of autonomous robots.   
     
     
         20 . The method of  claim 14 , wherein the first container is a cage comprising fencing along three walls, an open fourth wall, and a platform having slots configured to receive the one or more forks.